SolidCAM Application Tutorial
:
Port Machining
Contents
1. Introduction ... 1
2. CAM-Part Definition... 5
3. Stock and Target Definition ... 13
4. iMachining Operation ... 17
5. Roughing Operations ... 23
About this course
The goal of this course is to teach you how to use SolidCAM’s Port Machining to machine a simple and complex port. This tutorial covers the basic concepts of Port Machining. Once you have developed a good foundation in basic skills, you can refer to the online help for information on the less frequently used options.
Prerequisites
Students attending this course are expected to have basic knowledge of the SolidCAM software.
Course design
This course is designed around a task-based approach to training. The guided exercises will teach you the necessary commands and options to complete a machining task. The theoretical explanations are embedded into these exercises to give an overview of the Port Machining capabilities.
Using this book
This tutorial is intended to be used in a classroom environment under the guidance of an experienced instructor. It is also intended to be a self-study tutorial.
3 1. Introduction Port Machining
The Port Machining operation is an easy to use method for machining ports with tapered lollipop
tool, and has collision checks for the entire tool (shank, arbor, and holder). You can choose to cut the top only, the bottom only, and specify how much stock to leave on the entire port. It uses 3-Axis machining as far into the port as possible, and then switches to 5-Axis motion. Smooth transitions are created where the tool paths meet at the middle of the port. It provides both roughing and finishing tool paths to make ports from castings or billet.
The CAM-Part definition process for the part consists of the following stages:
• CAM-Part creation. At this stage, you have to define the CAM-Part name and location.
SolidCAM defines the necessary system files and a folder to allocate the place to store SolidCAM data.
• CNC-controller definition. It is necessary to choose the CNC-controller. The controller
type influences the Coordinate System definition and the Geometry definition.
• Coordinate System definition. You have to define the Coordinate System, which is the
origin for all machining operations of the CAM-Part. You can create multiple CoordSys positions and in each machining step select which CoordSys you want to use for the operation.
• Stock and Target definition. It is necessary to define a boundary of the stock that is used
for the CAM-Part machining. SolidCAM enables you to define the model of the part in its final stage after the machining.
The following exercises describe the full process of the CAM-Part definition. It is recommended to go through the stages in order to understand how the CAM-Part features are built. For this purpose, you have to turn off the automatic CAM-Part definition.
1. Browse to open the SolidWorks part PORT.SLDPRT.
2. Click Tools > SolidCAM > SolidCAM Settings.
CAM-Part creation
Coordinate System definition CNC-Machine definition
7 2. CAM-Part Definition
3. In the left pane, select CAM-Part.
4. Ensure that the settings are as shown in the
image:
This enables you to start directly adding operations in a new part.
5. In the left pane, select Automatic CAM-Part definition. In the right pane, click the Milling tab. 6. Ensure that all check boxes are cleared. 7. Click OK.
8. Click Tools > SolidCAM > New > Milling.
10. In the CNC-Machine list, click table_table_exercise.
11. Click Define button in the Coordinate System tab to set the
coordinate system for this part.
12. In the Place CoordSys origin to list, click Top center of model box.
13. Select the face as shown in the image. 14. Click
9 2. CAM-Part Definition
15. Enter the parameters as shown in the image. 16. Click OK.
17. Click 1-Position > Add.
18. In the Place CoordSys origin to list, click CoordSys # 1. 19. Select the face as shown in the image.
20. Click
The CoordSys Data window displays.
21. Enter the parameters as shown in the image. 22. Click
24. Click Edit iMachining Database in the iMachining Data section.
The iDatabase window displays.
25. Click the New icon to define a new machine.
26. Enter HERMLE_PORT as the machine name in the New iMachining DB File window.
27. Click Save.
28. Enter the parameters as shown in the
image.
29. Click the Material DB tab. 30. Click the New icon.
31. Enter AL-6061-T6 as the material name in the New iMachining DB File window.
11 2. CAM-Part Definition
33. Enter the MPa value of 460 as shown in the image. 34. Click Save & Exit.
35. In the iMachining Data section select the machine and material
you just defined.
36. Click in the Milling Part Data window.
Stock and Target
To define the stock you have to follow the steps mentioned in this chapter.
1. Click the Feature Manager Design Tree icon. 2. Click Design Model > Solid Bodies(3) > Stock > Show.
3. The selected stock should look as shown in the
image:
4. Click the SolidCAM Manager icon.
15 3. Stock and Target Definition
6. In the Defined by list, click 3D Model.
7. Select the solids as shown in the image.
8. Enter the Facet tolerance value as 0.1 so that your
system does not create a big faceting file.
9. Click
10. Click Target > Define.
11. Select the solid as shown in the image. 12. Click
iMachining
1. Right click Operations > Machine Setup.
The Machine Setup window displays.
2. Enter a value of 225 as shown in the Z column. This will raise the part above the machining
level.
3. Click OK.
4. Click the Feature Manager Design Tree icon. 5. Click Design Model > STOCK > Hide.
6. Click the SolidCAM Manager icon.
7. Right click Setup > Add Milling Operation > 2D iMachining.
19 4. iMachining Operation
You can also add the 2D iMachining operation,by clicking the SolidCAM Operations tab > iMachining > 2DMachining.
Or, by clicking the SolidCAM 2.5D tab > 2D iMachining.
8. In the Technology list, click iRough. 9. Click Geometry.
10. In the CoordSys list, click MAC 1 (2-Position). 11. Click the New icon under CoordSys.
12. Select the two contours as shown in the
image.
13. Click Yes in the OK to accept? window both
the times.
14. Click
15. Click Tool > Select.
16. Click the Add Milling Tool icon. 17. Select END MILL.
18. Enter the parameters as shown in the
image.
19. Select the Holder check box. 20. Select HSK A 63 ER 32x80. 21. Click the iData tab.
22. In the Topology / Helical Angle list,
click 35 (Standard). 23. Click
24. Click Levels. 25. Click Upper Level.
26. Select the face as shown in the image. 27. Click
28. Click Pocket depth.
29. Select the point on the face as shown in the image. 30. Click
21 4. iMachining Operation
31. Click Technology.
32. Set the Wall / island offset as 0.1.
33. In the Finish section, select the Floor check box. 34. Click Link.
35. Slide the Max. arc size slide bar to around 6.19764.
Ensure that the Advanced check box is selected. 36. Click the Save & Calculate icon.
37. Click the Exit icon.
Before you start the roughing operation, you must make a few changes to close the holes as shown in the image.
1. Right click > Edit part.
2. Click Insert > Surface > Offset.
3. Enter a value of 0 in the Offset Parameters field to make a copy of
25 5. Roughing operations
4. Select the five faces as shown in the video. 5. Click
6. Click the Feature Manager Design Tree icon.
7. Click Solid Bodies(3) > PART >Hide.
9. Select the two faces as shown in the image. 10. Select the Internal edges option in the Options
section.
11. Click
12. Click Insert > Surface > Untrim.
13. Select the face as shown in the image.
14. Select the All edges option in the Options section. 15. Click
27 5. Roughing operations
16. Click Insert > Curve > Split Line.
17. Click the Feature Manager Design Tree icon.
18. Click Design Model > Plane4.
19. Click once in the section highlighted in green color.
20. Select the four faces as shown in the video. 21. Select the Intersection option in the Type of Split
section.
22. Click
23. Click Sketch > 3D Sketch. 24. Click the Line icon.
25. Select the two points as shown in the image. 26. Click the esc (escape) key on your keyboard. 27. Click to come out of the sketch.
28. Click Insert > Surface > Fill.
Ensure that in the Feature Manager Design Tree, Surface-Fill3, 3DSketch3 is switched
on.
29. Select the three edges as shown in the video. 30. Click
This will ensure that you have three distinct tubes available for machining.
31. Click to finish editing the part. 32. Click the SolidCAM Manager icon.
33. Right click the previous operation > Add Milling Operation > Port Machining. 34. In theTechnologylist, clickRoughing.
29 5. Roughing operations
37. Select the faces as shown in the video. 38. Click
39. Set the Offset value as 0.5. 40. Click Tool > Select.
41. Click the Add Milling Tool icon. 42. Enter the parameters as shown in
the image.
43. Select the Holder check box. 44. Select HSK A 63 ER 32x80 as the
holder.
45. Click 46. Click Levels.
47. Click the Parallel to X option to get a cylinder parallel to the X axis. 48. Click the three points button, next to
49. Select the point as shown in the image. 50. Click
51. Enter the Retract distance value in the Levels section as shown
in the image.
52. Click Tool path parameters.
53. Enter the values as shown in the image. 54. Click the Sorting tab.
55. In the Output type list, click Top.
56. In the Machine to list, click Maximum from top. 57. Click Tool axis control.
31 5. Roughing operations
59. Click Gouge check.
60. Select the Check surfaces check box.
61. Ensure that in the Feature Manager Design Tree, PART is switched on. 62. Click the New icon under Check surfaces.
63. Select the faces as shown in the image. 64. Click
65. Click Clearance data.
66. Enter the parameters as shown in the
image.
67. Click the Save & Calculate icon. 68. Click the Simulate icon.
69. Click the Play icon in the Simulation
window.
The tool path should look as shown in the image.
70. Click the Save, Parallel Calculate & Copy icon. 71. Click Geometry.
72. Click the New icon underMachining surfaces. 73. Select the faces as shown in the image.
74. Click
75. Click Gouge check.
76. Select the Check surfaces check box.
77. Click the New icon under Check surfaces. 78. Select the faces as shown in the image.
79. Click
80. Click Clearance data.
81. Enter the parameters as shown in the
33 5. Roughing operations
82. Click the Save & Calculate icon. 83. Click the Simulate icon.
84. Click the Play icon in the Simulation window.
The tool path should look as show in the image.
Click the Exit icon.
85. Click the Exit icon to come out of the Operations Manager. 86. Right click > Copy the operation.
87. Right click > Paste the operation. 88. Right click > Edit the operation.
89. Click Geometry.
90. Click the New icon underMachining surfaces. 91. Select the faces as shown in the video.
92. Click
93. Click Tool path parameters. 94. Click the Sorting tab.
95. In the Output type list, click Bottom.
96. In the Machine to list, click Maximum from bottom. 97. Click the Feature Manager Design Tree icon. 98. Click Solid Bodies(3) > PART >Show.
99. Click Tool axis control.
100. Unselect the Minimize tilting check box.
101. Click Gouge check.
35 5. Roughing operations
103. Select the highlighted surface. 104. Click
105. Click Clearance data.
106. Enter the parameters as shown in the
image.
107. Click the Save & Calculate icon. 108. Click the Simulate icon.
109. Click the Play icon in the Simulation window.
The tool path should look as show in the image.
110. Right click the operation > Add Milling Operation > 3D HSR. 111. In the Technology list, click Contour roughing.
112. Click CoordSys on Geometry page.
113. Go to the Feature Manager Design Tree and switch on the PART. 114. Click 2-Position > Add.
115. In the Place CoordSys origin to list, click Top center of model box. 116. Select the face as shown in the image.
117. In the Modify by pick section, select the Pick XY origin check
box.
37 5. Roughing operations
119. In the Modify by flip section, click the Flip around Z button
twice.
120. Click
The CoordSys Data window displays.
121. Enter the parameters as shown in the image. 122. Click
123. Click to close the CoordSys Manager window. 124. Click Tool > Select.
125. Click the Add Milling Tool icon. 126. Select BULL NOSE MILL as the tool.
127. Enter the parameters as shown in the
image.
128. Select the Holder check box. 129. Select HSK A 63 ER 32x80. 130. Click
131. Click Constraint boundaries. 132. Select the Created manually option. 133. In the list, click User-defined boundary.
134. Click the New icon under Boundary name. 135. Select the boundary as shown in the image. 136. Click Yes in OK to accept? window. 137. Click
138. Click Passes.
139. Enter the parameters as shown in the
image.
39 5. Roughing operations
141. Select the point as shown in the image. 142. Click
143. Click the Adaptive step down tab.
144. In the Adapt Step down by list, click None. 145. Click Link.
146. Click the Ramping tab.
147. Enter the parameters as shown in the
image.
148. Click the Retracts tab.
149. Select the Minimal vertical retract
option.
150. Click the Save & Calculate icon. 151. Click the Simulate icon.
152. Click the Play icon in the Simulation window.
The tool path should look as show in the image.
153. Click the Exit icon to close the Simulation window.
1. Right click the operation > Add Milling Operation > Port Machining. 2. In the Technology list, click Spiral Finishing.
3. Click Geometry. 4. In the list, click faces.
The selected faces should look as shown in the image. You have earlier used this geometry in the roughing operation. The name in your file may differ than what is mentioned in the tutorial. Therefore, from the list, select the faces as shown in the image.
5. Click Tool > Select.
6. Select the LOLLIPOP MILL tool from the
list.
7. Click Levels.
8. Click the Parallel to X option to get a cylinder parallel to the X axis. 9. Click
10. Select the point as shown in the image. 11. Click
43 6. Finishing Operations
12. Enter the value in the Levels section as shown in the image. 13. Click Tool path parameters.
14. Click the Sorting tab.
15. In the Output type list, click Top.
16. In the Machine to list, click Maximum from top. 17. Click Gouge check.
18. In the Check surfaces list, click faces1.
The selected face should be as shown in the image. The name in your file may differ than what is mentioned in the tutorial. Therefore, from the list, select the faces as shown in the image.
19. Click Clearance data.
20. Enter the parameters as shown in the
image.
21. Click the Save & Calculate icon. 22. Click the Simulate icon.
The tool path should look as show in the image.
24. Click the Exit icon. 25. Click the Exit icon.
26. Right click > Copy the operation. 27. Right click > Paste the operation. 28. Right click > Edit the operation.
29. In the Technology list, click Plunge Finishing. 30. Click Geometry.
31. In the list, click faces2.
The selected faces should look as shown in the image. You have earlier used this geometry in the roughing operation. The name in your file may differ than what is mentioned in the tutorial. Therefore, from the list, select the faces as shown in the image.
45 6. Finishing Operations
32. Click Tool path parameters. 33. Click the Sorting tab.
34. Enter the parameters as shown in the
image.
35. Click Tool axis control.
36. Unselect the Minimize tilting check box. 37. Click Gouge check.
38. Click the New icon under Check surfaces. 39. Select the highlighted faces.
40. Click
41. Click Clearance data.
42. Enter the parameters as shown in the
image.
43. Click the Save & Calculate icon. 44. Click the Simulate icon.
The tool path should look as show in the image.
46. Click the Exit icon. 47. Click the Exit icon.
48. Right click the operation >Copy. 49. Right click the operation > Paste. 50. Right click the operation > Edit.
51. In the Technology list, click Spiral Finishing. 52. Click Geometry.
53. In the list, click faces4.
The selected faces should look as shown in the image. You have earlier used this geometry in the roughing operation. The name in your file may differ than what is mentioned in the tutorial. Therefore, from the list, select the faces as shown in the image.
47 6. Finishing Operations
54. Change the Offset value to 0. 55. Click Tool > Select.
56. Select the LOLLIPOP MILL tool from the list. 57. Click Tool path parameters.
58. Set the Maximum step over limit as 1. 59. Click the Sorting tab.
60. In the Output type list, click Bottom.
61. In the Machine to list, click Maximum from bottom. 62. Click Gouge check.
63. In the Check surfaces list, click faces5.
The selected face must look as shown in the image. The name in your file may differ than what is mentioned in the tutorial. Therefore, from the list, select the faces as shown in the image.
64. Click Clearance data.
65. Enter the parameters as shown in the
66. Click the Save & Calculate icon. 67. Click the Simulate icon.
68. Click the Play icon in the Simulation window.
The tool path should look as show in the image.
69. Click the Exit icon. 70. Click the Exit icon.
71. Right click the operation > Add Milling Operation > 3D HSM. 72. In the Technology list, click Helical machining.
73. In the CoordSys list, click MAC 1 (3-Position) as the user coordinate system. 74. Click Tool > Select.
75. Select the LOLLIPOP MILL tool from the list. 76. Click Constraint boundaries.
49 6. Finishing Operations
79. In the Boundary name list, click contour.
The selected boundary must look as shown in the image. The name in your file may differ than what is mentioned in the tutorial. Therefore, from the list, select the contour as shown in the image.
80. Click Passes.
81. Enter the parameters as shown in the
image.
82. Click Z-Top.
83. Select the point as shown in the image. 84. Click
85. Select the Adaptive step down tab. 86. Enter the parameters as shown in the
87. Click Link.
88. Click the Retracts tab.
89. Click the Minimal vertical retract option. 90. Click the Save & Calculate icon. 91. Click the Simulate icon.
92. Click the Play icon in the Simulation window.
The tool path should look as show in the image.
93. Click the Exit icon. 94. Click the Exit icon.
iMachining 2D 2.5D Milling HSS (High-Speed Surface Machining)
iMachining 3D Indexed Multi-Sided Machining HSM (High-Speed Machining)
Simultaneous 5-Axis Machining Turning & Advanced Mill-Turn Solid Probe
SolidCAM Application Tutorial:
Port Machining
www.youtube.com/SolidCAMProfessor www.youtube.com/SolidCAMiMachining
